Continuous Improvement Specialist

Your Contribution

The Continuous Improvement Specialist (AutoStore Focus) is responsible for optimizing warehouse operations through the effective use, continuous improvement, and performance enhancement of the AutoStore automated storage and retrieval system (AS/RS). This role drives operational efficiency, throughput, and inventory accuracy by combining Lean methodologies with deep system knowledge and data-driven decision-making.

The ideal candidate will serve as a key liaison between operations, facilities/maintenance, engineering, IT, and automation partners to ensure operational performance is maximized and continuously improved.

This role is responsible to:

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Key Responsibilities

AutoStore System Optimization

• Monitor and analyze AutoStore system performance including throughput, bin utilization, robot efficiency, and downtime.
• Primary point of contact for AutoStore support including troubleshooting, Logbase, IDOC’s, server issues, and integration topics.
• Primary point of contact for Logbase support including access requests, ticket management, software updates, and other improvements.
• Identify bottlenecks and implement improvements to maximize system capacity and performance.
• Optimize system parameters such as task allocation, picking strategies, and inventory slotting.
• Support system upgrades, expansions, and configuration changes.

Continuous Improvement Initiatives

• Lead CI projects targeting improvements in productivity, order fulfillment, inventory accuracy, and system uptime.
• Identify cost improvements, document business case, track and report cost savings and CAPEX spending related to projects improving warehouse material flow, inventory, key performance indicators, value stream optimization, business processes, and operating standards, including those not related to Autostore.
• Apply Lean tools (e.g., root cause analysis, value stream mapping, waste elimination) to automated and manual workflows.
• Project Management per Project Management Cockpit, including budget planning, recurring meetings, cross functional teams, identification of risks and open items/action tracker.

Automation & Process Integration

• Analyze and optimize workflows between AutoStore and surrounding operations (inbound, picking, packing, and shipping). Implement robotics, AGV’s, conveyors, and other automation tools.
• Identify opportunities to improve material flow, reduce handling time, and enhance system integration.
• Collaborate with system integrators, vendors, and IT teams to improve functionality and performance. This includes but is not limited to packaging, tote utilization, and box standardization within operations.

Data Analysis & Performance Monitoring

• Develop and maintain dashboards to track key metrics such as:
• System throughput (bins/hour, picks/hour)
• Robot utilization and availability
• System downtime and error rates
• Order fulfillment cycle time
• Other operational areas outside of Autostore
• Use data analytics to identify trends, predict issues, and drive proactive improvements.

Problem Solving & Reliability

• Lead troubleshooting and root cause analysis of system issues, including mechanical, software, and operational disruptions.
• Work closely with maintenance and engineering teams to improve system reliability and reduce downtime.
• Implement preventive and corrective actions to ensure consistent performance.
• Troubleshoot IDOC communications and resolve errors.

Employee Engagement & Training

• Train and coach operations teams on best practices for working with AutoStore systems.
• Support development of standard operating procedures (SOPs) related to automated operations.
• Promote participation in continuous improvement initiatives, including employee suggestion programs.

Cross-Functional Collaboration

• Partner with Operations, Maintenance/Facilities, Engineering, IT, and Supply Chain to align system performance with business goals.
• Support new product introductions, layout changes, and volume shifts affecting AutoStore operations.
• Back up CI Specialists for Digitalization and MPS
• Support site visits and collaborate with peers to create messaging content and internal presentations, tour support, and creation of boards for tours.
• Assist to carry out Layered Process Audits and Gemba Walks
• Share best practices and support benchmarking across sites using AutoStore lessons learned and technology.

Your Experience & Qualifications

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• Bachelor’s degree in Engineering, Operations, or related field
• 3–7+ years of experience in warehouse operations, automation, or continuous improvement roles
• Experience with AutoStore or similar automated storage systems (AS/RS) strongly preferred

Technical Skills

• Strong understanding of warehouse automation systems and material flow
• Experience with data analysis tools (Excel, Power BI, or similar)
• Familiarity with WMS, ERP systems, and automation interfaces
• Knowledge of Lean manufacturing / Lean logistics principles
• CAD Drawings for project concepts

Certifications (Preferred)

• Lean Six Sigma (Green Belt or Black Belt)
• Experience in automation or systems engineering environments

Our Offering

We will provide a collaborative environment working on exciting assignments, along with ongoing personal & career development opportunities. We encourage you to apply even if you don't meet every single requirement. You may just be the right candidate for this or other roles!

After receiving your online application, the interview process will typically be a screening call followed by Personal Interview(s)

For more information about MAHLE and what a career with us looks like for you, click here. and to learn more about our foundation owned technology group click here.

#DiversityMatters with our inclusive culture, we welcome applications from all social, religious & ethnical backgrounds, disabilities both mental and physical, identities (gender) and neurodivergent people.

MAHLE is not currently hiring individuals for this position who now or in the future require sponsorship for employment-based non-immigrant and immigrant visas. However, as a global company, MAHLE offers many job opportunities outside of USA which can be found through our employment website www.jobs.mahle.com

Do you have any questions?

MEGHA.A.GUPTA@MAHLE.COM